3D Thermoplastic Composite Pultrusion System and Method

ABSTRACT

A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/864,544, filed Sep. 24, 2015, which claims priority to U.S.Provisional Patent Application No. 62/128,376, filed on Mar. 4, 2015,all of which are incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates to 3D pultrusion systems and methods.

BACKGROUND OF THE INVENTION

In recent times, advances have been made in thermoplastic 3D printingusing CNC technology and 3-axis positioning. These 3D printing machinesallow a wide variety of shapes to be produced with nothing more than aCAD drawing. That is, they have the advantage of creating a complexshape without a mold.

SUMMARY OF THE INVENTION

An aspect of the invention involves a 3D pultrusion system and methodbased upon a 3D/variable die system to continuously producethermoplastic composite pultrusions with at least one of varyingcross-section geometry and constant surface contours, varyingcross-section geometry and varying surface contours, and constantcross-section geometry and varying surface contours.

The 3D pultrusion system and method enables a myriad of industries, fromautomotive, industrial, and aerospace to create continuous, automatedcomplex shapes using only CAD programs and CNC processing without theneed for expensive molds.

Another aspect of the invention involves a 3D thermoplastic pultrusionsystem. The pultrusion system comprises one or more sets of 3Dthermoplastic forming machines; and a CNC control system controlling theone or more sets of 3D thermoplastic forming machines to form a heatedprepreg thermoplastic composite material into a 3D thermoplasticcomposite pultrusion.

One or more implementations of the aspect of the invention recitedimmediately above includes one more of the following: The 3Dthermoplastic composite pultrusion has varying cross-section geometryand constant surface contours. The 3D thermoplastic composite pultrusionhas a constant cross-section geometry and varying surface contours. The3D thermoplastic composite pultrusion has a varying cross-sectiongeometry and varying surface contours. 23. The 3D thermoplasticcomposite pultrusion has varying surface contours in both a pultrusiondirection and 90 degrees to the pultrusion direction. The 3Dthermoplastic composite pultrusion is created without molds. The one ormore sets of 3D thermoplastic forming machines include a plurality ofCNC actuators and a flexible chilled band shapeable by the CNC actuatorsto form the heated prepreg thermoplastic composite material into thethermoplastic composite pultrusion. Swivel joints connect the pluralityof CNC actuators to the chilled band. The CNC control system includes acomputer system having a computer readable medium configured to storeexecutable programmed modules; a processor communicatively coupled withthe computer readable medium configured to execute programmed modulesstored therein; one or more computer programmed module elements storedin the computer readable medium and configured to be executed by theprocessor, wherein the one or more computer programmed module elementsconfigured to at least one of extend and retract the CNC actuators. TheCNC control system at least one of extends and retracts the CNCactuators with an accuracy of +/−0.001 inches. The CNC control systemincludes a computer system having a computer readable medium configuredto store executable programmed modules; a processor communicativelycoupled with the computer readable medium configured to executeprogrammed modules stored therein; one or more computer programmedmodule elements stored in the computer readable medium and configured tobe executed by the processor, wherein the one or more computerprogrammed module elements configured to command the plurality ofactuators to specific location to flex and contour the chilled band. Amaterial advancement system incrementally advances the thermoplasticcomposite pultrusion an incremental amount and the CNC control systemincludes a computer system having a computer readable medium configuredto store executable programmed modules; a processor communicativelycoupled with the computer readable medium configured to executeprogrammed modules stored therein; one or more computer programmedmodule elements stored in the computer readable medium and configured tobe executed by the processor, wherein the one or more computerprogrammed module elements configured to control the 3D thermoplasticforming machines so that the chilled band consolidate the heated prepregthermoplastic composite material into a specific shape for eachincrement of material advancement. The one or more sets of 3Dthermoplastic forming machines are disposed above and below the heatedprepreg thermoplastic composite material. The 3D thermoplasticpultrusion system continuously produces at least one of complex bodypanels such as doors and hoods, aircraft body panels, luggagecompartments, airplane interior sections, aerodynamic surfaces, complexpiping, duct-work, and any component that currently requires a largemold. The heated prepreg thermoplastic composite material includes afiber composite material including a first sandwich skin, a secondsandwich skin, an interior core, and distinct groups of 3D Z-axis fibersthat extend from the first sandwich skin to the second sandwich skin,linking the sandwich skins together. The flexible chilled band includesa release material. The 3D thermoplastic forming machines disposed aboveand below the heated prepreg thermoplastic composite material includethe flexible chilled band. The 3D thermoplastic forming machines includeservo motors that the CNC actuators are operatively coupled with. The 3Dthermoplastic forming machines include pivot points that the actuatorsrotate about. The 3D thermoplastic forming machines include thrustingand retracting plates attached to the actuators. The 3D thermoplasticpultrusion system includes a heated die and the 3D thermoplasticpultrusion system is downstream of the heated die.

An additional aspect of the invention involves a method of creating a 3Dthermoplastic composite pultrusion with a 3D thermoplastic pultrusionsystem including one or more sets of 3D thermoplastic forming machines.The method comprises providing composite material including one or morethermoplastic composite tapes; heating the composite material includingone or more thermoplastic composite tapes with a heating mechanism; andcontrolling the one or more sets of 3D thermoplastic forming machineswith a CNC control system to form the heated composite materialincluding one or more thermoplastic composite tapes into a 3Dthermoplastic composite pultrusion.

One or more implementations of the aspect of the invention recitedimmediately above includes one more of the following: The method furtherincludes incrementally advancing the formed 3D thermoplastic compositepultrusion with a material advancement system. The 3D thermoplasticcomposite pultrusion has a varying cross-section geometry and constantsurface contours. The 3D thermoplastic composite pultrusion has constantcross-section geometry and varying surface contours. The 3Dthermoplastic composite pultrusion has a varying cross-section geometryand varying surface contours. The 3D thermoplastic composite pultrusionhas varying surface contours in both a pultrusion direction and 90degrees to the pultrusion direction. The 3D thermoplastic compositepultrusion is created without molds. The one or more sets of 3Dthermoplastic forming machines include a plurality of CNC actuators anda flexible chilled band shapeable by the CNC actuators, and controllingincludes shaping the flexible chilled band to form the 3D thermoplasticcomposite pultrusion with the plurality of CNC actuators. The 3Dthermoplastic pultrusion system includes swivel joints connecting theplurality of CNC actuators to the chilled band. The CNC control systemincludes a computer system, and the method further includes at least oneof controlling extending and retracting the CNC actuators with thecomputer system. The CNC control system at least one of extends andretracts the CNC actuators with an accuracy of +/−0.001 inches. The CNCcontrol system includes a computer system, and the method furtherincludes commanding the plurality of actuators to specific location toflex and contour the chilled band with the computer system. The methodfurther includes incrementally advancing the formed 3D thermoplasticcomposite pultrusion with a material advancement system and wherein theCNC control system includes a computer system, and the method furtherincludes controlling the 3D thermoplastic forming machines with thecomputer system so that the chilled band consolidates the heatedcomposite material composite material into a specific shape for eachincrement of material advancement. The method further includes formingthe 3D thermoplastic composite pultrusion with the one or more sets of3D thermoplastic forming machines disposed above and below the heatedcomposite material. The heated composite material includes a fibercomposite material including a first sandwich skin, a second sandwichskin, an interior core, and distinct groups of 3D Z-axis fibers thatextend from the first sandwich skin to the second sandwich skin, linkingthe sandwich skins together. The method further includes adding arelease material to the flexible chilled band. The 3D thermoplasticforming machines disposed above and below the heated composite materialinclude the flexible chilled band. The 3D thermoplastic forming machinesinclude servo motors that the CNC actuators are operatively coupledwith. The 3D thermoplastic forming machines include pivot points thatthe actuators rotate about. The 3D thermoplastic forming machinesinclude thrusting and retracting plates attached to the actuators. The3D thermoplastic composite pultrusion is at least one of complex bodypanels such as doors and hoods, aircraft body panels, luggagecompartments, airplane interior sections, aerodynamic surfaces, complexpiping, duct-work, and any component that currently requires a largemold.

A further aspect of the invention involves an airfoil manufactured by aprocess. The process comprises providing composite material includingone or more thermoplastic composite tapes; heating the compositematerial including one or more thermoplastic composite tapes with aheating mechanism; and controlling one or more sets of 3D thermoplasticforming machines with a CNC control system to form the heated compositematerial including one or more thermoplastic composite tapes into theairfoil.

One or more implementations of the aspect of the invention describedimmediately above includes one or more of the following: The processfurther includes incrementally advancing the formed airfoil with amaterial advancement system. The airfoil has a varying cross-sectiongeometry and constant surface contours. The airfoil has constantcross-section geometry and varying surface contours. The 3Dthermoplastic composite pultrusion has a varying cross-section geometryand varying surface contours. The airfoil has varying surface contoursin both a pultrusion direction and 90 degrees to the pultrusiondirection. The process of manufacturing the airfoil is performed withoutmolds. The one or more sets of 3D thermoplastic forming machines includea plurality of CNC actuators and a flexible chilled band shapeable bythe CNC actuators, and controlling includes shaping the flexible chilledband to form the airfoil with the plurality of CNC actuators. Theairfoil further includes swivel joints connecting the plurality of CNCactuators to the chilled band. The CNC control system includes acomputer system, and the process further includes at least one ofcontrolling extending and retracting the CNC actuators with the computersystem. The CNC control system at least one of extends and retracts theCNC actuators with an accuracy of +/−0.001 inches. The CNC controlsystem includes a computer system, and the process further includescommanding the plurality of actuators to specific location to flex andcontour the chilled band with the computer system. The process furtherincludes incrementally advancing the formed airfoil with a materialadvancement system and wherein the CNC control system includes acomputer system, and the process further includes controlling the 3Dthermoplastic forming machines with the computer system so that thechilled band consolidates the heated composite material compositematerial into a specific shape for each increment of materialadvancement. The process further includes forming the airfoil with theone or more sets of 3D thermoplastic forming machines disposed above andbelow the heated composite material. The heated composite materialincludes a fiber composite material including a first sandwich skin, asecond sandwich skin, an interior core, and distinct groups of 3D Z-axisfibers that extend from the first sandwich skin to the second sandwichskin, linking the sandwich skins together. The process further includesadding a release material to the flexible chilled band. The 3Dthermoplastic forming machines disposed above and below the heatedcomposite material include the flexible chilled band. The 3Dthermoplastic forming machines include servo motors that the CNCactuators are operatively coupled with. The 3D thermoplastic formingmachines include pivot points that the actuators rotate about. The 3Dthermoplastic forming machines include thrusting and retracting platesattached to the actuators.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings, which are incorporated in and form a part ofthis specification illustrate embodiments of the invention and togetherwith the description, serve to explain the principles of the invention.

FIG. 1A is a diagram of an embodiment of an exemplary thermoplasticcomposite tape pultrusion process in which the thermoplastic pultrusiondie system and method of the present invention may be incorporated intoin one application.

FIG. 1B is a side elevation view of an embodiment showing an end of adie and die cavity gap (end being defined as the exit of the die as onewould view the die system from the position of the pultrusion grippers)of an embodiment of the thermoplastic pultrusion die system and method.

FIG. 2 is a graph showing how the embodiment of the thermoplasticpultrusion die system and method shown in FIG. 1B can operate steadystate at some predefined load cell reading, which is a closed loopcontrol and feedback on the opening of the die cavity gap, andsynchronized with the pultrusion speed.

FIG. 3 is a graph similar to FIG. 2 in which a further embodiment ispossible with the thermoplastic pultrusion die system and method. Inthis embodiment, the thermoplastic pultrusion die system and methodallow for temporary halting of the gripper speed while high-compressionforces are temporarily applied to the part.

FIG. 4 is a graph similar to FIG. 3, except that in this embodiment ofthe thermoplastic pultrusion die system and method a rapid servo controland high frequency of the change in die cavity gap occurs in a mannerthat does not require the grippers to be stopped.

FIG. 5 is a graph similar to FIG. 3, and shows how the thermoplasticpultrusion die system and method could react to an anomaly such as asplice, a knot in a wood core, or other disruption causing excessive diepressures.

FIG. 6 is a side elevation view similar to FIG. 1B of an alternativeembodiment of a thermoplastic pultrusion die system and method withmultiple CNC type servo actuators and load cells installed over a verywide die top, a very wide plate, and a very wide strongback.

FIG. 7 is a side elevation view similar to FIG. 6 of an alternativeembodiment of a thermoplastic pultrusion die system and method, exceptthat the CNC motors and actuators have been replaced with servo CNChydraulic cylinders and a sandwich panel is shown.

FIG. 8 is a side elevation view similar to FIG. 7 of a furtherembodiment of a thermoplastic pultrusion die system and method, exceptthat the interior of the die is spherically curved.

FIG. 9 is a perspective view of an embodiment of a rhombictriacontahedron composite radome.

FIGS. 10A-10E are perspective views of different stages of sphericalthermoplastic composite sandwich panels processed in a small sphericaldie similar to that as shown in FIG. 8 and exiting the die along thedefined spherical path into curved spherical composite sandwich panelsusing the thermoplastic pultrusion die system of FIG. 8.

FIG. 11 is a block diagram illustrating an example computer system thatmay be used in connection with various embodiments described herein.

FIG. 12A shows an embodiment of a 3D thermoplastic forming machine.

FIG. 12B shows the 3D thermoplastic forming machine of FIG. 12A withbands retracted and the thermoplastic prepreg material shown in asomewhat arched shape.

FIG. 13 shows a section of an embodiment of a thermoplastic compositeresulting from the 3D thermoplastic composite pultrusion system andmethod.

FIG. 14 shows a section of another embodiment of a thermoplasticcomposite resulting from the 3D thermoplastic composite pultrusionsystem and method where the thermoplastic composite is not only curvedbut also has a twist.

FIG. 15 shows a cross-sectional view of an embodiment of a structuralsandwich panel or fiber composite material wall of a surface or partproduced by a method described herein.

DESCRIPTION OF EMBODIMENT OF THE INVENTION

With reference to FIGS. 1-8, before describing embodiments of a 3Dthermoplastic pultrusion forming machine/apparatus and method, anembodiment of a thermoplastic pultrusion die system (“system”) 300 andmethod of processing using the same will first be described. The 3Dthermoplastic pultrusion forming machine/apparatus and method is animprovement on the system 300 and method.

With reference to FIG. 1A, before describing the system 300, anembodiment of an exemplary thermoplastic composite tape pultrusionprocessing assembly 310 and method that the thermoplastic pultrusion diesystem 300 and method may be a part of will first be described.

In the thermoplastic composite tape pultrusion processing assembly 310,the pultrusion process moves from left to right. From left-to-right, theassembly 310 includes a tunnel oven 315, the thermoplastic pultrusiondie system 300, and a pultrusion gripper mechanism including one or moregrippers (e.g., one, two, three) 309, 311, 313 in series. In FIG. 1A, afairly short thermoplastic pultrusion die system 300 is shown, but inactuality the thermoplastic pultrusion die system 300 may extend forwardin the process 20 feet or more to assist with heating of multiple tapesor plies of thermoplastic tape to achieve faster line speeds on theprocessing.

The one or more grippers 309, 311, 313 pull a solid part 302 from thethermoplastic pultrusion die system 300 by clamping and pulling in ahand-over-hand method, using either a combination of one, two or threegrippers at a time. In an alternative embodiment, a mechanical motivetransmitter other than one or more grippers is used such as, but not byway of limitation, nip rollers or a caterpillar dive system.

Raw material 304 includes a composite material including one or morethermoplastic composite tapes entering the thermoplastic pultrusion diesystem 300. Before raw material 304 enters the thermoplastic pultrusiondie system 300, upstream of the thermoplastic pultrusion die system 300,the thermoplastic composite tapes are preheated in a pre-heatingmechanism (e.g., tunnel oven) 315, which can be heated to a temperaturejust below a melt temperature of the thermoplastic resin of thethermoplastic composite tapes.

As the pultruded tape material exits the thermoplastic pultrusion diesystem 300, it is chilled and consolidated, as represented by the solidpart 302. The transition from a series of individual thermoplasticcomposite tapes to the solid part 302 takes place in the thermoplasticpultrusion die system 300.

The thermoplastic pultrusion die system 300 preferably includes aheating mechanism (e.g., heater or hot zone) in the front of thethermoplastic pultrusion die system 300 heated by platens 330 using aseries of heaters and controllers 335. At an end of thermoplasticpultrusion die system 300, just before the pultruded tape materialexits, is a cooling mechanism (e.g., cooler or chilling zone) providedby chilling platens 340, which are physically attached to thermoplasticpultrusion die system 300. The platens 340 have a cooling water circuit342 designed to carry cooling fluids such as water to a radiatingsystem, shown here with a fan 345. In alternative embodiments,alternative heating mechanisms and/or cooling mechanism may be used withthe thermoplastic pultrusion die system 300. A computer system 338controls one of more of the components of the assembly 310.

With reference to FIG. 1B, the thermoplastic pultrusion die system 300is a die, platen, and frame arrangement. The thermoplastic pultrusiondie system 300 is shown in elevation in FIG. 1B as if viewing from thepultrusion grippers 309, 311, 313 towards the downstream end of thethermoplastic pultrusion die system 300.

The thermoplastic pultrusion die system 300 includes a die bottom 30(supported by a lower support 18) and a die top 31 separated by a diecavity gap 47. The die top 31 is bolted to the die bottom 30 at boltholes 45. Along opposite edges of the die bottom 30 and die top 31 areelongated, narrow flat silicone seals 40. Load cells 8 are supposed bythe lower support 18 are measure the load pressure at various locationsin the thermoplastic pultrusion die system 300. The load cells 8 areoperably coupled to CNC servo motors 4 via ball screws 6. A strongback 2and a platen 14 move with rotation of the ball screws (and areassociated with the die top 31 and/or die bottom 30) to increase ordecrease the die cavity gap 47.

FIG. 1B shows the assembly of the die halves with the silicone seal 40and the ball screws 6 with servo motors 4 and load cells 8, as one wouldview the system 300 prior to connecting the die top 31 to the siliconeseal 40 and prior to actuating the platen 14 and the strongback 2 intointimate contact with the die top 31.

FIG. 1B illustrates the die cavity gap 47 at an exit end of thethermoplastic pultrusion die system 300. Once the die top 31 is boltedto the die bottom 30 at the bolt holes 45 shown on each the left andright hand sides of the die, then the die cavity gap 47 will be a closedcavity, but for the opening at the entrance of the die (not shown) andthe opening at the exit (shown as 47 in FIG. 1B).

An important aspect of the system 300 is the two pieces of silicone sealmaterial shown as 40 on both sides of the system 300. Although thesilicone seals 40 are shown as narrow, elongated strips of siliconematerial, in alternative embodiments, the silicone seals 40 may be anyshape/configuration. For example, but not by way of limitation, thesilicone seals 40 may be round and fit into somewhat circular slots ofmatting flanges of both die bottom 30 and die top 31. The bolts holdingthe die bottom 30 and the die top 31 together would pinch the siliconeseal 40. In the embodiment shown, a thread is disposed in die bottom 30and a slip fit in die top 31. The bolts can be tightened to give amaximum die cavity gap position and no more. The minimum die cavityposition is attained by actuating the platen 14, which is shown raisedabove the die top 31, but would be brought down into intimate contact byway of the actuated ball screws 6 that are shown on each side of thethermoplastic pultrusion die system 300. Although only two ball screws 6are shown in FIG. 1B, the thermoplastic pultrusion die system 300 mayinclude 4 or more actuated ball screws 6.

The platen 14 is attached to the bottom of the strongback 2, whichallows for a steady and well distributed downward force on the top ofthe thermoplastic pultrusion die system 300 when the ball screws 6 areactuated downward by the servo motors 4. The servo motors 4 arecontrolled by a CNC control system that command(s) a given positionthrough sophisticated motion control including, but not limited to,commanded acceleration, deceleration, and soft reversal of torque anddirection. When the downward force of the platen 14 depresses thesilicone seals 40, there is additional resistance of the thermoplastictape material, which is not shown in FIG. 1B for clarity, but would bein the entire die cavity gap 47. Since the silicone seals 40 aredesigned for high temperature and have good recovery after compression,the die cavity gap 47 remains sealed on the sides through the entireactuation cycle from maximum gap to minimum gap. The silicone seals 40can stretch or be compressed up to 800% without loosing its/theirelasticity.

Although the maximum die cavity gap 47 can be set by the bolts (in boltholds 45), a more preferred method is the use of the load cells 8 at theend of ball screws 6 to give a measure of calibrated die pressure. Ifthe weight of the die top 31 is great, it may be necessary in some casesto attach the die top 31 to the platen 14 and the strongback 2. In thisway, absolute minimum material pressure can be achieved when the ballscrews 6 are actuated upward. The goal will be to adjust the die cavitygap 47 to the proper height to achieve continuous pultrusion ofthermoplastic composite laminates, and when the situation calls for it,the system 300 can actively alternate between pultrusion and cycling thedie cavity gap 47, as well be described in more detail below.

Although the lower support 18 is shown as being fixed and secured toground/not deflectable, in one or more alternative embodiments, thesupport 18 is similar to the platen 14 and the strongback 2. Thus, inone or more embodiments, the system 300 may include an upper movable dietop/platen/strongback and/or a lower movable die top/platen/strongback.

Purposely not shown in FIG. 1B are the heating and cooling systems (theycan generally be seen in FIG. 1A), which include a heating zone in thecenter and generally forward sections of the system 300, top and bottom,and with a cooling section toward the rear, or discharge end of the die,both top and bottom. Multiple coordinated controls may be used tocontrol the system 300. If, for example, the system 300 of FIG. 1B hadfour ball screws 6 with four servo motors 4, the system 300 wouldinclude 4-axes of motion control. With the addition of three pultrusiongrippers (See FIG. 1A), the system 300 would include a minimum of a7-axis CNC system and process. The computer hardware and/or software tointerface with this system 300 will be generally described below withrespect to the exemplary computer system 550 described below withrespect to FIG. 11.

Once the embodiment of FIG. 1A is provided as a system 300, with the CNCmotion control, then the control schemes of FIGS. 2, 3, 4, and 5 can beimplemented. There are reasons to consider each, which will depend onfactors, such as, but not limited to, laminate thickness, laminatedensity, surface finish required, addition of foreign material (besidesthermoplastic tape) including the wide variety of core materials suchas, but not limited to, wood, concrete, gypsum, honeycomb, foam, andother foreign materials/cores that can be found in sandwich panelconstruction.

FIG. 2 shows the simplest control scheme for the system 300. Threedifferent graphs are shown versus time. The units in time can be any aspart of the pultrusion process. As shown in FIG. 2, the grippers 309,311, 313 are shown running at a consistent speed 130 somewhere betweentheir 100% design speed and 0% speed (stopped). The die cavity gap 47 isshown between some maximum specification gap and some minimumspecification gap 134. The load cell reading 138 is showing an effectiveinternal pressure via a constant load cell reading. This is similar tothermoplastic tape pultrusions run consistently with thick parts (0.303inches in thickness and 32 layers of Polystrand thermoplastic tape). Insuch a case, the die thickness that was machined was perfect. However,had it not been perfect, the frictional forces would have been too highor the consolidation would have been too low. In cases where the die isnot perfectly set to the correct die cavity gap, then the system 300 andmethod of the present invention can correct such a problem.

In the case of thin laminates, the adjustment of die cavity gap may bemandatory in achieving a perfect pultrusion. FIG. 2 simulates settingthe die cavity gap to the perfect thickness, as judged by numerouscriteria, as if a solid die was perfectly manufactured. The system 300of the present invention is critical in reducing the costs ofmanufacturing and trial and error in making the perfect die.Accordingly, FIG. 2 represents a system that duplicates a perfect diecavity gap, and has an important other benefit. In start-up, it isnecessary to open the cavity somewhat to make it easier to string-up thematerial at the start. Also, if splices ever are needed such as at theend of a pultrusion run, the pultrusion die system 300 can be slightlyopened temporarily. If an anomaly occurs, the control system would catchthe problem (such as the tape breaking at the inlet and suddenly havingless volume). In this case, the load cell 8 on the die top 31 wouldcatch a drop in consolidation pressures.

FIG. 3 shows a variation in software control that can be provided withthe identical system described with respect to FIG. 1. With thinlaminates, it is sometimes necessary to prevent the sloughing ofoff-axis tapes, such as +/−30 degrees, +/−45 degrees, or 90 degrees.This sloughing is caused by tight die cavity gaps, minimum material andhigh frictional forces. The graph of FIG. 3 is similar to FIG. 2. Theterm “pull-pression” is coined for the combination of pultrusion andcompression (molding). It should be noted that two different moments intime are shown with the vertical lines 70 and 75.

Line 70 in FIG. 3 shows a point in time where the gripper 309, 311, 313is pulling at 100% of design speed, indicated by 80. It is here wherethe die cavity gap 47 is most open or relaxed, as indicated by the peakin the curve 84. It so happens that the load cells 8 reading the diepressure will be at their lowest point 88.

As the grippers 309, 311, 313 move in a cycle, new raw material 304 isbeing pulled into the entrance of the pultrusion die system 300 and thefinished composite part 302 is being pulled from the exit of thepultrusion die system 300. After a discrete unit of time, the grippers309, 311, 313 suddenly stop and this occurs when the servo actuatorsapply commanded downward force on the die top 31 and the part iseffectively undergoing compression. At this point, the grippers 309,311, 313 are stopped at 0% speed 81 and the die cavity is compressed atcycle point 85 and the load cell(s) 8 indicate maximum compression 89.

It is at this point that the cycle repeats itself. At intervals, thematerial is in a relaxed condition and pulled into the pultrusion diesystem 300, then compressed at no speed, and then relaxed at 100% speed,and the process repeats itself. The pultrusion die system 300 starts outcold at the front (or partially heated below the melt point of thethermoplastic matrix). As the material moves its way down the pultrusiondie system 300, it encounters a hot zone designed to completely melt andconsolidate the part under pressure, and then further down towards thedie exit, the material is chilled or cooled and it is finished with itsconsolidation and eventually exits the cooled die as a finished section.

FIG. 4 is similar to FIG. 3. It should be noted that, in FIG. 4, thereare peak load cell readings 99 associated with the most compressed dielocations 95. Likewise, there are minimum load cell readings 98 thatcorrespond to relaxed positions on the die gap 94. Shown in FIG. 4 is avery high cyclic alternate actuation of servo controls to achieve thisrapid movement and the numbers could amount to several per second, withthe limitations of the actuation system and the ball screw travel. Inthis case, a small fraction of time allows the pultrusion speed to stayconstant and follow steady pultrusion speed. Using the system 300 andmethod, trial and error can be used to determine the optimum controlsequence.

FIG. 5 is similar to FIG. 3, except in FIG. 5 the control interrupts acompression event 121 when some interference (e.g., a thicker core orskin material) has entered the pultrusion die system 300 and now thefull compressed location 115 of the die cavity cannot be achieved as theload cell reading alarms the control system that maximum die pressurehas occurred early in the compression cycle. In this case, the actuatorswill not complete the compression until the load has returned to anacceptable level.

In many large pultrusion die systems, producing panels continuously andup to as much as 14 feet in width, it is difficult to pressure thematerial and keep the die surfaces at the same gap in the middle of thepultrusion die system 300 as the edges. In this case, as shown in FIG.6, the lines 50 are break lines and indicate a much wider die thanshown. A sample of an adjunct ball screw 206, load cell 208, and servomotor 204 are shown. This is shown inside a hole 214 which has beenplaced in the strongback, 2 and the plate 14. For a very wide pultrusiondie system 300, there may be several of these placed every 1, 2, 3, or 4feet (or other distance) apart across the width of the pultrusion diesystem 300 and these are there to achieve the same purpose as elements4, 6, and 8 in FIG. 6. These multiple actuators could allow forcontrolling die cavity gaps in the center of a wide, flat die, in whichany pressure would want to slightly open up the gap, due to hoop stressforces. There is a need for active CNC control of the die cavity gap 47over the entire panel width, and this will be especially important inthin and wide thermoplastic composites manufactured from the tapesdescribed herein.

FIG. 7 is a side elevation view similar to FIG. 6 of an alternativeembodiment of a thermoplastic pultrusion die system and method, exceptthat the CNC motors and actuators have been replaced with servo CNChydraulic cylinders 705. Also shown is a sandwich panel in a compressedstate, with skins 815 and core 810, in the compressed state as if thefull design pressure had been applied through the cylinders 705.

The servo-controlled hydraulic cylinders 705 can alternately close andopen the die cavity. When closing, the die cavity can move to a positionin which a given pressure is applied to the composite materials, whichif, for example, a 100 psi pressure is required and if cylinder(s) 705were incorporated into a centers-of-equal area, then one square foot, or144 square inches, requiring 100 psi, would mean a 4 inch diametercylinder 705 would operate at 1146.5 psi operating pressure. In otherwords, a single 4-inch cylinder 705 has 12.56 square inches of area, andat 1146.5 psi will deliver 14400 lbs., which is exactly 100 psi oflaminate die pressure over one square foot. Further to FIG. 7, thehydraulic cylinders 705 are intended to supply force at thecenters-of-equal area. As indicated above, the strong-back 2 supportsthe upper platen 14, wherein the lower platen 814 has hydrauliccylinders 705 pressing on same and reacted by the ground 210. The dietop 31 and die bottom 30 are shown in a compressed state, and as shownthere is no need for bolts 45 to attach to the die upper and lowersections.

FIG. 8 is a side elevation view similar to FIG. 7 of an alternativeembodiment of a thermoplastic pultrusion die system 900 and method. Theview of thermoplastic pultrusion die system 900 in FIG. 8 is of the exitof the die system 900, but a side view would show the same sphericalshape (i.e., die system 900 has interior spherical curve in bothlongitudinal and lateral directions of die system 900, which manifestsitself as an arc line when viewed, as in the case of FIG. 8 at just oneedge of the spherical die) and, thus, look similar to that shown in FIG.8. The above description and drawings of the thermoplastic pultrusiondie systems and methods with respect to FIGS. 1-7 are incorporatedherein and like elements are shown with like reference numbers.

In the embodiment shown, the thermoplastic pultrusion die system 900 andmethod are used to sequentially form from the input into the processingdie of flat thermoplastic composite sandwich panel material into 100%spherical-curved sandwich panels 904 that exit the processing die, whichare assembled together to form a rhombic triacontahedron compositeradome 906 such as that shown in FIG. 9 to protect a vast number ofradar installations, including military radar. The flat sandwich panelsinclude a foam core with top and bottom skins and as an option,3-dimensional fibers transit from one skin to the other, through thefoam. In alternative embodiments or implementations, the thermoplasticpultrusion die system 900 and method are used to post mold sandwichpanels for other applications, including panels of different sphericaldiameters and different cylindrical shapes, as well as complexcurvatures.

The thermoplastic pultrusion die system 900 includes a sphericallycurved die 910 in the shape of the defined spherical diameter of rhombictriacontahedron radome panels 906. The die 910 includes a die bottom 930with a curved, spherical, concave top surface 935 and die top 940 with acurved, spherical, convex bottom surface 945. Together, the curved,concave top surface 935 of the die bottom 930 and the curved, convexbottom surface 945 of the die top 940 form a curved spherical die cavitygap 947.

As shown in FIGS. 10A-10D, during the efficient in-line thermoplasticpultrusion method, the flat sandwich composite panels are processed intocontinuous curved, spherical sandwich composite panel parts 904. Thecurved sandwich composite panel parts 904 exiting the die system 900climb according to the curvature being formed. In the embodiment shown,the curved sandwich composite panel parts 904 are of the same length,size, and curvature and are assembled together to make the radome 906 toprotect military radar. In alternative embodiments, it may be desirableto make curved configurations/structures where one of more of the curvedpanels have a different curvature, length, and/or size. In a stillfurther embodiment, the convex and concave surfaces and die members arereversed, such that the spherical resultant panel exiting the diemembers curves in a downward direction.

With reference to FIG. 9, the rhombic triacontahedron composite radome906 is a sandwich panel radome of the A-Sandwich variety wherein thethin skins on each side are a thermoplastic resin matrix with glassencapsulating a foam core, and the combination of the thin skins and thefoam core are radio frequency (RF) transparent and sized to beapproximately ¼ the wavelength of the radar frequency of the militaryradar being protected. The radome 906 is made of spherical panels 904and is of the order of 30 feet to 60 feet in diameter, but clearly couldbe any diameter from 5 feet to 200 feet in dimension. Because the radome906 is a rhombic tricontrahedron radome, there is only one-sized panelto make the sphere. Because the radome 906 is a rhombic triacontahedronradome, there is only one-sized panel to make the sphere, excluding thetruncated panels that attach to a mounting ring or foundation, at 908,and each said truncated panel is made from a larger, aforementionedone-sized panel.

Hydrophobic films or coatings/paints can be applied to the outside ofthe radome sandwich part 904 prior to assembly to resist weathering andto keep the radome 906 clean and free of water droplets, in order toaffect the superior transmission capability of the radar.

To house the radome 906, there is a truncation of the dome, atapproximately 85% of the height/diameter of the radome 906, where amounting ring 908 is located and the radome 906 bolts, or is fastened,to the mounting ring 908 for structural stiffness and rigidity, and herethere is a set of different shaped panels, but each formed from the samebase-singular panel 904, to create the spherical radome 906. In analternative embodiment, the radome 906 is made of panels 904 having afew different configurations of a multitude of geodesic designsinvolving radome shapes, pentagons, hexagons, radome-shapes,oranger-peel shapes, and the like.

FIG. 11 is a block diagram illustrating an example computer system 550that may be used in connection with various embodiments describedherein. For example, the computer system 550 may be used in conjunctionwith the computer system(s), computer(s), control(s), controller(s),control system (e.g., software, and/or hardware). However, othercomputer systems and/or architectures may be used, as will be clear tothose skilled in the art.

The computer system 550 preferably includes one or more processors, suchas processor 552. Additional processors may be provided, such as anauxiliary processor to manage input/output, an auxiliary processor toperform floating point mathematical operations, a special-purposemicroprocessor having an architecture suitable for fast execution ofsignal processing algorithms (e.g., digital signal processor), a slaveprocessor subordinate to the main processing system (e.g., back-endprocessor), an additional microprocessor or controller for dual ormultiple processor systems, or a coprocessor. Such auxiliary processorsmay be discrete processors or may be integrated with the processor 552.

The processor 552 is preferably connected to a communication bus 554.The communication bus 554 may include a data channel for facilitatinginformation transfer between storage and other peripheral components ofthe computer system 550. The communication bus 554 further may provide aset of signals used for communication with the processor 552, includinga data bus, address bus, and control bus (not shown). The communicationbus 554 may comprise any standard or non-standard bus architecture suchas, for example, bus architectures compliant with industry standardarchitecture (“ISA”), extended industry standard architecture (“EISA”),Micro Channel Architecture (“MCA”), peripheral component interconnect(“PCI”) local bus, or standards promulgated by the Institute ofElectrical and Electronics Engineers (“IEEE”) including IEEE 488general-purpose interface bus (“GPIB”), IEEE 696/S-100, and the like.

Computer system 550 preferably includes a main memory 556 and may alsoinclude a secondary memory 558. The main memory 556 provides storage ofinstructions and data for programs executing on the processor 552. Themain memory 556 is typically semiconductor-based memory such as dynamicrandom access memory (“DRAM”) and/or static random access memory(“SRAM”). Other semiconductor-based memory types include, for example,synchronous dynamic random access memory (“SDRAM”), Rambus dynamicrandom access memory (“RDRAM”), ferroelectric random access memory(“FRAM”), and the like, including read only memory (“ROM”).

The secondary memory 558 may optionally include a hard disk drive 560and/or a removable storage drive 562, for example a floppy disk drive, amagnetic tape drive, a compact disc (“CD”) drive, a digital versatiledisc (“DVD”) drive, etc. The removable storage drive 562 reads fromand/or writes to a removable storage medium 564 in a well-known manner.Removable storage medium 564 may be, for example, a floppy disk,magnetic tape, CD, DVD, etc.

The removable storage medium 564 is preferably a computer readablemedium having stored thereon computer executable code (i.e., software)and/or data. The computer software or data stored on the removablestorage medium 564 is read into the computer system 550 as electricalcommunication signals 578.

In alternative embodiments, secondary memory 558 may include othersimilar means for allowing computer programs or other data orinstructions to be loaded into the computer system 550. Such means mayinclude, for example, an external storage medium 572 and an interface570. Examples of external storage medium 572 may include an externalhard disk drive or an external optical drive, or and externalmagneto-optical drive.

Other examples of secondary memory 558 may include semiconductor-basedmemory such as programmable read-only memory (“PROM”), erasableprogrammable read-only memory (“EPROM”), electrically erasable read-onlymemory (“EEPROM”), or flash memory (block oriented memory similar toEEPROM). Also included are any other removable storage units 572 andinterfaces 570, which allow software and data to be transferred from theremovable storage unit 572 to the computer system 550.

Computer system 550 may also include a communication interface 574. Thecommunication interface 574 allows software and data to be transferredbetween computer system 550 and external devices (e.g. printers),networks, or information sources. For example, computer software orexecutable code may be transferred to computer system 550 from a networkserver via communication interface 574. Examples of communicationinterface 574 include a modem, a network interface card (“NIC”), acommunications port, a PCMCIA slot and card, an infrared interface, andan IEEE 1394 fire-wire, just to name a few.

Communication interface 574 preferably implements industry promulgatedprotocol standards, such as Ethernet IEEE 802 standards, Fiber Channel,digital subscriber line (“DSL”), asynchronous digital subscriber line(“ADSL”), frame relay, asynchronous transfer mode (“ATM”), integrateddigital services network (“ISDN”), personal communications services(“PCS”), transmission control protocol/Internet protocol (“TCP/IP”),serial line Internet protocol/point to point protocol (“SLIP/PPP”), andso on, but may also implement customized or non-standard interfaceprotocols as well.

Software and data transferred via communication interface 574 aregenerally in the form of electrical communication signals 578. Thesesignals 578 are preferably provided to communication interface 574 via acommunication channel 576. Communication channel 576 carries signals 578and can be implemented using a variety of wired or wirelesscommunication means including wire or cable, fiber optics, conventionalphone line, cellular phone link, wireless data communication link, radiofrequency (RF) link, or infrared link, just to name a few.

Computer executable code (i.e., computer programs or software) is storedin the main memory 556 and/or the secondary memory 558. Computerprograms can also be received via communication interface 574 and storedin the main memory 556 and/or the secondary memory 558. Such computerprograms, when executed, enable the computer system 550 to perform thevarious functions of the present invention as previously described.

In this description, the term “computer readable medium” is used torefer to any media used to provide computer executable code (e.g.,software and computer programs) to the computer system 550. Examples ofthese media include main memory 556, secondary memory 558 (includinghard disk drive 560, removable storage medium 564, and external storagemedium 572), and any peripheral device communicatively coupled withcommunication interface 574 (including a network information server orother network device). These computer readable mediums are means forproviding executable code, programming instructions, and software to thecomputer system 550.

In an embodiment that is implemented using software, the software may bestored on a computer readable medium and loaded into computer system 550by way of removable storage drive 562, interface 570, or communicationinterface 574. In such an embodiment, the software is loaded into thecomputer system 550 in the form of electrical communication signals 578.The software, when executed by the processor 552, preferably causes theprocessor 552 to perform the inventive features and functions previouslydescribed herein.

Various embodiments may also be implemented primarily in hardware using,for example, components such as application specific integrated circuits(“ASICs”), or field programmable gate arrays (“FPGAs”). Implementationof a hardware state machine capable of performing the functionsdescribed herein will also be apparent to those skilled in the relevantart. Various embodiments may also be implemented using a combination ofboth hardware and software.

Furthermore, those of skill in the art will appreciate that the variousillustrative logical blocks, modules, circuits, and method stepsdescribed in connection with the above described figures and theembodiments disclosed herein can often be implemented as electronichardware, computer software, or combinations of both. To clearlyillustrate this interchangeability of hardware and software, variousillustrative components, blocks, modules, circuits, and steps have beendescribed above generally in terms of their functionality. Whether suchfunctionality is implemented as hardware or software depends upon theparticular application and design constraints imposed on the overallsystem. Skilled persons can implement the described functionality invarying ways for each particular application, but such implementationdecisions should not be interpreted as causing a departure from thescope of the invention. In addition, the grouping of functions within amodule, block, circuit or step is for ease of description. Specificfunctions or steps can be moved from one module, block or circuit toanother without departing from the invention.

Moreover, the various illustrative logical blocks, modules, and methodsdescribed in connection with the embodiments disclosed herein can beimplemented or performed with a general purpose processor, a digitalsignal processor (“DSP”), an ASIC, FPGA or other programmable logicdevice, discrete gate or transistor logic, discrete hardware components,or any combination thereof designed to perform the functions describedherein. A general-purpose processor can be a microprocessor, but in thealternative, the processor can be any processor, controller,microcontroller, or state machine. A processor can also be implementedas a combination of computing devices, for example, a combination of aDSP and a microprocessor, a plurality of microprocessors, one or moremicroprocessors in conjunction with a DSP core, or any other suchconfiguration.

Additionally, the steps of a method or algorithm described in connectionwith the embodiments disclosed herein can be embodied directly inhardware, in a software module executed by a processor, or in acombination of the two. A software module can reside in RAM memory,flash memory, ROM memory, EPROM memory, EEPROM memory, registers, harddisk, a removable disk, a CD-ROM, or any other form of storage mediumincluding a network storage medium. An exemplary storage medium can becoupled to the processor such the processor can read information from,and write information to, the storage medium. In the alternative, thestorage medium can be integral to the processor. The processor and thestorage medium can also reside in an ASIC.

With reference to FIGS. 12A-14, an embodiment of a 3D thermoplasticpultrusion forming machine/apparatus and method will be described.

Thermoplastic composite processing can be accomplished continuously byincrementally applying die pressure on preformed and prepreg materialwhile the part is not moving through the machine, then sequentiallyaltering between a release of the die surfaces/andmovement-to-open-die-surfaces, then a movement in a controlled fashionan incremental step forward, followed again by zero line speed and aclamping force applied.

This can be seen by examining FIG. 3, showing clamping and line speedalternating as the continuous process proceeds. The part then moves froma heated die at predetermined temperatures to a chilled die also at predetermined temperatures, and then when exiting the chilled die the partis fully consolidated.

Replacing the die, which initially is flat, as shown and described withrespect to FIGS. 1B, 6, and 7, with a spherical or cylindrical die, asshown and described with respect to FIG. 8, one can make curved shapescontinuously. A 32-foot diameter radome with thermoplastic sandwichpanels manufactured in the process system described above wassuccessfully manufactured and installed.

Applicant has recognized that a need exists to manufacture a complexshape that has varying contours, such as a propeller for a smallairplane. This is not a flat panel, a spherical panel or a purecylindrical panel, and the shape of the propeller is a complex curvaturesurface that the state of the art would dictate a mold be produced andthe material either vacuum bag-produced, or match mold produced, or thelike. Applicant has also recognized that a need exists to produce acomplex shape from the continuous system the Applicant has developed.

Similar to the embodiments shown herein and described above, where athermoplastic composite prepreg or the like is sequentially consolidatedat a “melt” temperature as the part is pulled forward, the 3Dthermoplastic pultrusion system and method includes a thermoplasticcomposite prepreg or the like that is sequentially consolidated at a“melt” temperature as the part is pulled forward, but, at the exit ofthe heated section of the die, as the chilled section is entered, thechilled section of the die is replaced with a new CNC actuated band thatvaries the lateral contour of the part as it exits the entire die. Thisvery small and incremental die shape can be changed, both top andbottom, by computer code implemented by a computer system (e.g.,computer system 550 shown in FIG. 11) that commands actuators to changethe shape of these chilled pressing bands, gradually and incrementally.

With reference to FIGS. 12A to 14, an embodiment of the 3D thermoplasticpultrusion system and method will now be described in more detail. The3D thermoplastic pultrusion system and method allows any complex shapeto be produced continuously without the need for expensive dies andnet-shape-molds, in automotive industries it will be possible tocontinuously manufacture complex body panels such as doors and hoods; inthe aerospace industry one can manufacture aircraft body panels, luggagecompartments and airplane interior sections; and in the industrialmarkets, one can now manufacture any component that currently requires alarge mold, including complex piping and duct-work.

The 3D thermoplastic pultrusion system and method may include the systemshown in FIG. 1A, where heating occurs at the front section and chillingoccurs at the rear section, but the 3D thermoplastic pultrusion systemand method has only heating and adds a new component of CNC equipment,as shown in FIG. 12A, that is placed and positioned just downstream ofthe heated die. The thermoplastic composite section has been thoroughlyconsolidated, worked and pressed, and is now ready to be chilled into afinal shape. As the shape enters the device of FIG. 12A, the followingtakes place:

CNC actuators and motors are positioned with a motion control program toextend, or retract actuators with an accuracy of +/−0.001 inches;

these actuators are connected through a swivel joint to a chilled band;

the band has the ability to flex and contour as multiple actuators arecommanded to specific locations;

the chilled band can consolidate the hot prepreg thermoplastic compositematerial into a specific shape for each small increment of materialadvancement;

below the prepreg composite material is a similar set of motion controlmotors and actuators, along with a similar chilled band;

now an inside and outside shape can be defined and the chilled bands cantake the shape and additionally, pressure can be applied from theactuators such that the composite material is cooled and consolidatedbetween the upper and lower bands.

Further description of this process will be described following a briefdescription of FIGS. 12A, 12B, 13 and 14.

In FIG. 12A, the 3D thermoplastic forming machine is shown. The upperchilled forming band 1040 and the lower chilled forming band 1042 areshown retracted from the thermoplastic prepreg material 1044. Althoughnot shown, there may be a silicone release material between the bandsand the composite to facilitate release and avoid sticking of thethermoplastic to the band material. Both upper chilled forming band 1040and the lower chilled forming band 1042 are flexible. That is, they arerigid, yet flexible and can curve depending on the force that issupplied by actuators 1020, 1021, 1022, 1023, 1024, and 1025. Thecommanded position comes from a computer and motion control programimplemented by a computer system (e.g., computer system 550 shown inFIG. 11) such that the servo motors 1010, 1011, 1012, 1013, 1014, and1015 move the thrusting and retracting plates attached to the actuatorsand identified as 1050, 1051, 1052, 1053, 1054, and 1055.

Attached to these thrusting and retracting plates is a pivot linkagethat is attached to the chilling bands. The upper chilling band 1040 haspivots 1060, 1061, and 1062 and the lower chilling band 1042 has pivots1063, 1064, and 1065.

When the chilled bands for a large curved surface as commanded by theCNC program, a secondary pivot may be necessary that allows theactuators 1020, 1021, 1022, 1023, 1024, and 1025 to rotate. Thisaccomplished by bearings, or the like shown as 1030, 1031, 1032, 1033,1034, and 1035. In FIG. 12A, the chilled bands are shown in theretracted position. Additionally the source for chilling the bands,whether fluid cooling and transfer or air flow, is not shown forclarity. But there are numerous systems available to constantly removeheat from the bands and maintain a chilled temperature (inthermoplastics a “chilled” temperature may be as high as 180 degrees F.,which in thermoplastics technology is “chilled”).

FIG. 12B shows the bands 1040 and 1042 having been retracted, but notethe thermoplastic prepreg material is now in a somewhat arched shape asdefined by the CNC program. Note the pivots of 1060 and 1062 haverotated, as have the pivots 1063 and 1065. Additionally the actuatorbearings show a rotation of the actuators at 1030 and 1032 as well as1033 and 1035. The central actuators, 1021 and 1024 have not pivoted asthey remain in a position that is midway on the arc of the material.

Shown in FIG. 12B is the arch of the prepreg composite identified as1046. The significance of this can be realized when looking at FIG. 13.Note that the straight section of thermoplastic composite 1044 in FIG.12A is shown as 1044 in FIG. 13, and the curved thermoplastic composite1046 in FIG. 12B is shown as 1046 in FIG. 13.

Assume the composite part in FIG. 13 is 12 inches wide by 48 incheslong. Note that the chilled composite of FIG. 13 is gradually curvedfrom the flat section at 1044 to the curved section at 1046. Thismachine has incrementally formed this composite. As shown and describedrespect to FIG. 1A, the material is pulled by grippers a very shortdistance and the process is stopped incrementally to allow this CNCactuation. This advancement may be very small increments (as low as0.005 inches or less). The finer the increments, the smoother thematerial. In fact, the chilled bands may be replaced with a small wireto consolidate and chill the thermoplastic over a very small length. Inthis way, the process is creating a truly 3D die shape that iscontinually changing in small increments.

Because the instantaneous chilling by the chilled bands defines thesurface contour in the Y-direction (along the band and 90 degrees to thepultrusion direction), varying contours occur in the X-direction, or thepultrusion direction, by changing the CNC code for each incrementalpulling in the pultrusion direction; the varying surface contour is inboth directions, making a “compound” shape.

Now an inside and outside shape can be defined and the chilled bands cantake the shape and additionally pressure can be applied from theactuators such that the composite material is cooled and consolidatedbetween the upper and lower bands. In this disclosure with respect toFIGS. 12A-14, a part is actually a sandwich panel that is being formedand the contour shown in FIG. 13 is an aerodynamic surface that is thepressure side of a public domain airfoil, the NACA series 65 airfoil,which has been, over the years, thoroughly defined and thoroughlytested. In this case, there is a core and two skins that form thesandwich panel that is being dynamically shaped. Note that Applicant's3D fiber technology shown in FIG. 18, wherein 3D fibers tie the core tothe skins may be used for this aerodynamic surface of FIG. 13. As shownin FIG. 18, the surface is a structural sandwich panel or fibercomposite material wall. Each wall includes a first sandwich skin 131, asecond sandwich skin 133, interior foam core 135, and distinct groups137 of 3D Z-axis fibers that extend from the first sandwich skin 131 tothe second sandwich skin 133, linking the sandwich skins 131, 135together. The 3D insertions of fiber is described in applicant's U.S.Pat. Nos. 7,056,576, 7,217,453, 7,731,046, 7,785,693, 7,846,528,7,387,147, 6,676,785, 6,645,333, 7,105,071, 8,002,919, and 8,272,188,which are incorporated by reference herein.

It is important to note that the curved surface and composite shape ofFIG. 13 was created with this new machine and a CAD program, feedinginto a motion control program and most significantly there were no moldsmanufactured for this specific shape. An infinite number of shapes canbe made with this machine and zero molds are needed. Additionally, in afurther aspect, the heated die shown and described with respect to FIGS.1-8 is a variable curvature die, operating in a similar fashion to thechilled bands 1040 and 1042.

The 3D thermoplastic pultrusion system and method is significantlyimportant to US industry. Automotive doors can be made in rapid fashionand tooling can be minimized. In the aircraft industry, one can now makepropellers from thermoplastic composite, by simply programming amachine. Note that FIG. 14 shows a thermoplastic composite that is notonly curved but has a twist. Once formed the propeller could be machinedalong 1110, shown in FIG. 14, and with very little post processing, becompleted into a finished composite propeller. Note that this can beaccomplished with no molds.

The example computer system 550 shown and described with respect to FIG.11 provides the computer control described here for the 3D thermoplasticpultrusion system and method.

The above figures may depict exemplary configurations for the invention,which is done to aid in understanding the features and functionalitythat can be included in the invention. The invention is not restrictedto the illustrated architectures or configurations, but can beimplemented using a variety of alternative architectures andconfigurations. Additionally, although the invention is described abovein terms of various exemplary embodiments and implementations, it shouldbe understood that the various features and functionality described inone or more of the individual embodiments with which they are described,but instead can be applied, alone or in some combination, to one or moreof the other embodiments of the invention, whether or not suchembodiments are described and whether or not such features are presentedas being a part of a described embodiment. Thus the breadth and scope ofthe present invention, especially in the following claims, should not belimited by any of the above-described exemplary embodiments.

Terms and phrases used in this document, and variations thereof, unlessotherwise expressly stated, should be construed as open ended as opposedto limiting. As examples of the foregoing: the term “including” shouldbe read as mean “including, without limitation” or the like; the term“example” is used to provide exemplary instances of the item indiscussion, not an exhaustive or limiting list thereof; and adjectivessuch as “conventional,” “traditional,” “standard,” “known” and terms ofsimilar meaning should not be construed as limiting the item describedto a given time period or to an item available as of a given time, butinstead should be read to encompass conventional, traditional, normal,or standard technologies that may be available or known now or at anytime in the future. Likewise, a group of items linked with theconjunction “and” should not be read as requiring that each and everyone of those items be present in the grouping, but rather should be readas “and/or” unless expressly stated otherwise. Similarly, a group ofitems linked with the conjunction “or” should not be read as requiringmutual exclusivity among that group, but rather should also be read as“and/or” unless expressly stated otherwise. Furthermore, although item,elements or components of the disclosure may be described or claimed inthe singular, the plural is contemplated to be within the scope thereofunless limitation to the singular is explicitly stated. The presence ofbroadening words and phrases such as “one or more,” “at least,” “but notlimited to” or other like phrases in some instances shall not be read tomean that the narrower case is intended or required in instances wheresuch broadening phrases may be absent.

We claim:
 1. An airfoil manufactured by a process, the processcomprising: providing composite material including one or morethermoplastic composite tapes; heating the composite material includingone or more thermoplastic composite tapes with a heating mechanism;controlling one or more sets of 3D thermoplastic forming machines with aCNC control system to form the heated composite material including oneor more thermoplastic composite tapes into the airfoil.
 2. The airfoilof claim 1, the process further including incrementally advancing theformed airfoil with a material advancement system.
 3. The airfoil ofclaim 1, wherein the airfoil has at least one of varying cross-sectiongeometry and constant surface contours, varying cross-section geometryand varying surface contours, and constant cross-section geometry andvarying surface contours.
 4. The airfoil of claim 1, wherein the airfoilhas varying surface contours in both a pultrusion direction and 90degrees to the pultrusion direction.
 5. The airfoil of claim 1, whereinthe process of manufacturing the airfoil is performed without molds. 6.The airfoil of claim 1, wherein the one or more sets of 3D thermoplasticforming machines include a plurality of CNC actuators and a flexiblechilled band shapeable by the CNC actuators, and controlling includesshaping the flexible chilled band to form the airfoil with the pluralityof CNC actuators.
 7. The airfoil of claim 6, further including swiveljoints connecting the plurality of CNC actuators to the chilled band. 8.The airfoil of claim 6, wherein the CNC control system includes acomputer system, and the process further includes at least one ofcontrolling extending and retracting the CNC actuators with the computersystem.
 9. The airfoil of claim 8, wherein the CNC control system atleast one of extends and retracts the CNC actuators with an accuracy of+/−0.001 inches.
 10. The airfoil of claim 6, wherein the CNC controlsystem includes a computer system, and the process further includescommanding the plurality of actuators to specific location to flex andcontour the chilled band with the computer system.
 11. The airfoil ofclaim 6, wherein the process further includes incrementally advancingthe formed airfoil with a material advancement system and wherein theCNC control system includes a computer system, and the process furtherincludes controlling the 3D thermoplastic forming machines with thecomputer system so that the chilled band consolidates the heatedcomposite material composite material into a specific shape for eachincrement of material advancement.
 12. The airfoil of claim 6, whereinthe process further includes forming the airfoil with the one or moresets of 3D thermoplastic forming machines disposed above and below theheated composite material.
 13. The airfoil of claim 1, wherein theheated composite material includes a fiber composite material includinga first sandwich skin, a second sandwich skin, an interior core, anddistinct groups of 3D Z-axis fibers that extend from the first sandwichskin to the second sandwich skin, linking the sandwich skins together.14. The airfoil of claim 1, wherein the process further includes addinga release material to the flexible chilled band.
 15. The airfoil ofclaim 12, wherein the 3D thermoplastic forming machines disposed aboveand below the heated composite material include the flexible chilledband.
 16. The airfoil of claim 6, wherein the 3D thermoplastic formingmachines include servo motors that the CNC actuators are operativelycoupled with.
 17. The airfoil of claim 6, wherein the 3D thermoplasticforming machines include pivot points that the actuators rotate about.18. The airfoil of claim 6, wherein the 3D thermoplastic formingmachines include thrusting and retracting plates attached to theactuators.